US7468319B2 - Method for preventing a metal corrosion in a semiconductor device - Google Patents
Method for preventing a metal corrosion in a semiconductor device Download PDFInfo
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- US7468319B2 US7468319B2 US11/179,455 US17945505A US7468319B2 US 7468319 B2 US7468319 B2 US 7468319B2 US 17945505 A US17945505 A US 17945505A US 7468319 B2 US7468319 B2 US 7468319B2
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- metal layer
- aluminum
- metal
- etching
- layer
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- 229910052751 metal Inorganic materials 0.000 title claims abstract description 81
- 239000002184 metal Substances 0.000 title claims abstract description 81
- 238000000034 method Methods 0.000 title claims abstract description 61
- 239000004065 semiconductor Substances 0.000 title claims abstract description 23
- 230000007797 corrosion Effects 0.000 title claims abstract description 19
- 238000005260 corrosion Methods 0.000 title claims abstract description 19
- 229920002120 photoresistant polymer Polymers 0.000 claims abstract description 28
- 238000005530 etching Methods 0.000 claims abstract description 18
- 230000001590 oxidative effect Effects 0.000 claims abstract description 6
- 229910052782 aluminium Inorganic materials 0.000 claims description 28
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 28
- 239000007789 gas Substances 0.000 claims description 14
- 230000004888 barrier function Effects 0.000 claims description 13
- 239000006117 anti-reflective coating Substances 0.000 claims description 10
- 238000004380 ashing Methods 0.000 claims description 10
- ZAMOUSCENKQFHK-UHFFFAOYSA-N Chlorine atom Chemical compound [Cl] ZAMOUSCENKQFHK-UHFFFAOYSA-N 0.000 claims description 9
- 239000000460 chlorine Substances 0.000 claims description 9
- 229910052801 chlorine Inorganic materials 0.000 claims description 9
- 239000011261 inert gas Substances 0.000 claims description 9
- 238000001020 plasma etching Methods 0.000 claims description 7
- 239000010936 titanium Substances 0.000 claims description 7
- 229910000838 Al alloy Inorganic materials 0.000 claims description 6
- KZBUYRJDOAKODT-UHFFFAOYSA-N Chlorine Chemical compound ClCl KZBUYRJDOAKODT-UHFFFAOYSA-N 0.000 claims description 6
- 238000000992 sputter etching Methods 0.000 claims description 6
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 claims description 5
- XPDWGBQVDMORPB-UHFFFAOYSA-N Fluoroform Chemical compound FC(F)F XPDWGBQVDMORPB-UHFFFAOYSA-N 0.000 claims description 4
- 229910000676 Si alloy Inorganic materials 0.000 claims description 4
- 238000001312 dry etching Methods 0.000 claims description 4
- 239000000758 substrate Substances 0.000 claims description 4
- CSDREXVUYHZDNP-UHFFFAOYSA-N alumanylidynesilicon Chemical compound [Al].[Si] CSDREXVUYHZDNP-UHFFFAOYSA-N 0.000 claims description 3
- WPPDFTBPZNZZRP-UHFFFAOYSA-N aluminum copper Chemical compound [Al].[Cu] WPPDFTBPZNZZRP-UHFFFAOYSA-N 0.000 claims description 3
- 229910052786 argon Inorganic materials 0.000 claims description 3
- 229910052734 helium Inorganic materials 0.000 claims description 3
- 229910052743 krypton Inorganic materials 0.000 claims description 3
- 229910044991 metal oxide Inorganic materials 0.000 claims description 3
- 150000004706 metal oxides Chemical class 0.000 claims description 3
- 229910052754 neon Inorganic materials 0.000 claims description 3
- 229910052704 radon Inorganic materials 0.000 claims description 3
- 229910052724 xenon Inorganic materials 0.000 claims description 3
- RWSOTUBLDIXVET-UHFFFAOYSA-N Dihydrogen sulfide Chemical compound S RWSOTUBLDIXVET-UHFFFAOYSA-N 0.000 claims 1
- UQZIWOQVLUASCR-UHFFFAOYSA-N alumane;titanium Chemical compound [AlH3].[Ti] UQZIWOQVLUASCR-UHFFFAOYSA-N 0.000 claims 1
- -1 aluminum-copper-silicon Chemical compound 0.000 claims 1
- 229940101532 meted Drugs 0.000 claims 1
- 239000010410 layer Substances 0.000 description 63
- 230000008569 process Effects 0.000 description 16
- 125000001309 chloro group Chemical group Cl* 0.000 description 12
- YCKRFDGAMUMZLT-UHFFFAOYSA-N Fluorine atom Chemical compound [F] YCKRFDGAMUMZLT-UHFFFAOYSA-N 0.000 description 6
- 239000011737 fluorine Substances 0.000 description 6
- 229910052731 fluorine Inorganic materials 0.000 description 6
- 238000007254 oxidation reaction Methods 0.000 description 6
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 description 5
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 5
- 230000015572 biosynthetic process Effects 0.000 description 4
- 229910000041 hydrogen chloride Inorganic materials 0.000 description 4
- IXCSERBJSXMMFS-UHFFFAOYSA-N hydrogen chloride Substances Cl.Cl IXCSERBJSXMMFS-UHFFFAOYSA-N 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 4
- 230000003647 oxidation Effects 0.000 description 4
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- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 3
- 229910015844 BCl3 Inorganic materials 0.000 description 3
- 230000007547 defect Effects 0.000 description 3
- 238000011065 in-situ storage Methods 0.000 description 3
- FAQYAMRNWDIXMY-UHFFFAOYSA-N trichloroborane Chemical compound ClB(Cl)Cl FAQYAMRNWDIXMY-UHFFFAOYSA-N 0.000 description 3
- KLZUFWVZNOTSEM-UHFFFAOYSA-K Aluminium flouride Chemical compound F[Al](F)F KLZUFWVZNOTSEM-UHFFFAOYSA-K 0.000 description 2
- 239000000956 alloy Substances 0.000 description 2
- 229910045601 alloy Inorganic materials 0.000 description 2
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 2
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- 229910018125 Al-Si Inorganic materials 0.000 description 1
- 229910018182 Al—Cu Inorganic materials 0.000 description 1
- 229910018520 Al—Si Inorganic materials 0.000 description 1
- 229910018575 Al—Ti Inorganic materials 0.000 description 1
- VHUUQVKOLVNVRT-UHFFFAOYSA-N Ammonium hydroxide Chemical compound [NH4+].[OH-] VHUUQVKOLVNVRT-UHFFFAOYSA-N 0.000 description 1
- 229910018594 Si-Cu Inorganic materials 0.000 description 1
- 229910008465 Si—Cu Inorganic materials 0.000 description 1
- 229910004339 Ti-Si Inorganic materials 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- 229910010978 Ti—Si Inorganic materials 0.000 description 1
- 229910021529 ammonia Inorganic materials 0.000 description 1
- 125000004429 atom Chemical group 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
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- 230000003247 decreasing effect Effects 0.000 description 1
- 238000006731 degradation reaction Methods 0.000 description 1
- 239000008367 deionised water Substances 0.000 description 1
- 229910021641 deionized water Inorganic materials 0.000 description 1
- RWRIWBAIICGTTQ-UHFFFAOYSA-N difluoromethane Chemical compound FCF RWRIWBAIICGTTQ-UHFFFAOYSA-N 0.000 description 1
- 238000001704 evaporation Methods 0.000 description 1
- 238000005755 formation reaction Methods 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
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- 239000000203 mixture Substances 0.000 description 1
- 229910000069 nitrogen hydride Inorganic materials 0.000 description 1
- 229910052756 noble gas Inorganic materials 0.000 description 1
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- 238000000059 patterning Methods 0.000 description 1
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- 229910052719 titanium Inorganic materials 0.000 description 1
Images
Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
- H01L21/02—Manufacture or treatment of semiconductor devices or of parts thereof
- H01L21/02104—Forming layers
- H01L21/02365—Forming inorganic semiconducting materials on a substrate
- H01L21/02612—Formation types
- H01L21/02614—Transformation of metal, e.g. oxidation, nitridation
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
- H01L21/70—Manufacture or treatment of devices consisting of a plurality of solid state components formed in or on a common substrate or of parts thereof; Manufacture of integrated circuit devices or of parts thereof
- H01L21/71—Manufacture of specific parts of devices defined in group H01L21/70
- H01L21/768—Applying interconnections to be used for carrying current between separate components within a device comprising conductors and dielectrics
- H01L21/76838—Applying interconnections to be used for carrying current between separate components within a device comprising conductors and dielectrics characterised by the formation and the after-treatment of the conductors
- H01L21/76886—Modifying permanently or temporarily the pattern or the conductivity of conductive members, e.g. formation of alloys, reduction of contact resistances
- H01L21/76888—By rendering at least a portion of the conductor non conductive, e.g. oxidation
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
- H01L21/02—Manufacture or treatment of semiconductor devices or of parts thereof
- H01L21/02041—Cleaning
- H01L21/02057—Cleaning during device manufacture
- H01L21/02068—Cleaning during device manufacture during, before or after processing of conductive layers, e.g. polysilicon or amorphous silicon layers
- H01L21/02071—Cleaning during device manufacture during, before or after processing of conductive layers, e.g. polysilicon or amorphous silicon layers the processing being a delineation, e.g. RIE, of conductive layers
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
- H01L21/02—Manufacture or treatment of semiconductor devices or of parts thereof
- H01L21/02104—Forming layers
- H01L21/02107—Forming insulating materials on a substrate
- H01L21/02109—Forming insulating materials on a substrate characterised by the type of layer, e.g. type of material, porous/non-porous, pre-cursors, mixtures or laminates
- H01L21/02112—Forming insulating materials on a substrate characterised by the type of layer, e.g. type of material, porous/non-porous, pre-cursors, mixtures or laminates characterised by the material of the layer
- H01L21/02123—Forming insulating materials on a substrate characterised by the type of layer, e.g. type of material, porous/non-porous, pre-cursors, mixtures or laminates characterised by the material of the layer the material containing silicon
- H01L21/02142—Forming insulating materials on a substrate characterised by the type of layer, e.g. type of material, porous/non-porous, pre-cursors, mixtures or laminates characterised by the material of the layer the material containing silicon the material containing silicon and at least one metal element, e.g. metal silicate based insulators or metal silicon oxynitrides
- H01L21/02145—Forming insulating materials on a substrate characterised by the type of layer, e.g. type of material, porous/non-porous, pre-cursors, mixtures or laminates characterised by the material of the layer the material containing silicon the material containing silicon and at least one metal element, e.g. metal silicate based insulators or metal silicon oxynitrides the material containing aluminium, e.g. AlSiOx
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
- H01L21/02—Manufacture or treatment of semiconductor devices or of parts thereof
- H01L21/027—Making masks on semiconductor bodies for further photolithographic processing not provided for in group H01L21/18 or H01L21/34
- H01L21/0271—Making masks on semiconductor bodies for further photolithographic processing not provided for in group H01L21/18 or H01L21/34 comprising organic layers
- H01L21/0273—Making masks on semiconductor bodies for further photolithographic processing not provided for in group H01L21/18 or H01L21/34 comprising organic layers characterised by the treatment of photoresist layers
- H01L21/0274—Photolithographic processes
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
- H01L21/02—Manufacture or treatment of semiconductor devices or of parts thereof
- H01L21/04—Manufacture or treatment of semiconductor devices or of parts thereof the devices having at least one potential-jump barrier or surface barrier, e.g. PN junction, depletion layer or carrier concentration layer
- H01L21/18—Manufacture or treatment of semiconductor devices or of parts thereof the devices having at least one potential-jump barrier or surface barrier, e.g. PN junction, depletion layer or carrier concentration layer the devices having semiconductor bodies comprising elements of Group IV of the Periodic System or AIIIBV compounds with or without impurities, e.g. doping materials
- H01L21/30—Treatment of semiconductor bodies using processes or apparatus not provided for in groups H01L21/20 - H01L21/26
- H01L21/302—Treatment of semiconductor bodies using processes or apparatus not provided for in groups H01L21/20 - H01L21/26 to change their surface-physical characteristics or shape, e.g. etching, polishing, cutting
- H01L21/306—Chemical or electrical treatment, e.g. electrolytic etching
- H01L21/3065—Plasma etching; Reactive-ion etching
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
- H01L21/02—Manufacture or treatment of semiconductor devices or of parts thereof
- H01L21/04—Manufacture or treatment of semiconductor devices or of parts thereof the devices having at least one potential-jump barrier or surface barrier, e.g. PN junction, depletion layer or carrier concentration layer
- H01L21/18—Manufacture or treatment of semiconductor devices or of parts thereof the devices having at least one potential-jump barrier or surface barrier, e.g. PN junction, depletion layer or carrier concentration layer the devices having semiconductor bodies comprising elements of Group IV of the Periodic System or AIIIBV compounds with or without impurities, e.g. doping materials
- H01L21/30—Treatment of semiconductor bodies using processes or apparatus not provided for in groups H01L21/20 - H01L21/26
- H01L21/31—Treatment of semiconductor bodies using processes or apparatus not provided for in groups H01L21/20 - H01L21/26 to form insulating layers thereon, e.g. for masking or by using photolithographic techniques; After treatment of these layers; Selection of materials for these layers
- H01L21/3105—After-treatment
- H01L21/311—Etching the insulating layers by chemical or physical means
- H01L21/31127—Etching organic layers
- H01L21/31133—Etching organic layers by chemical means
- H01L21/31138—Etching organic layers by chemical means by dry-etching
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
- H01L21/02—Manufacture or treatment of semiconductor devices or of parts thereof
- H01L21/04—Manufacture or treatment of semiconductor devices or of parts thereof the devices having at least one potential-jump barrier or surface barrier, e.g. PN junction, depletion layer or carrier concentration layer
- H01L21/18—Manufacture or treatment of semiconductor devices or of parts thereof the devices having at least one potential-jump barrier or surface barrier, e.g. PN junction, depletion layer or carrier concentration layer the devices having semiconductor bodies comprising elements of Group IV of the Periodic System or AIIIBV compounds with or without impurities, e.g. doping materials
- H01L21/30—Treatment of semiconductor bodies using processes or apparatus not provided for in groups H01L21/20 - H01L21/26
- H01L21/31—Treatment of semiconductor bodies using processes or apparatus not provided for in groups H01L21/20 - H01L21/26 to form insulating layers thereon, e.g. for masking or by using photolithographic techniques; After treatment of these layers; Selection of materials for these layers
- H01L21/3205—Deposition of non-insulating-, e.g. conductive- or resistive-, layers on insulating layers; After-treatment of these layers
- H01L21/321—After treatment
- H01L21/3213—Physical or chemical etching of the layers, e.g. to produce a patterned layer from a pre-deposited extensive layer
- H01L21/32133—Physical or chemical etching of the layers, e.g. to produce a patterned layer from a pre-deposited extensive layer by chemical means only
- H01L21/32135—Physical or chemical etching of the layers, e.g. to produce a patterned layer from a pre-deposited extensive layer by chemical means only by vapour etching only
- H01L21/32136—Physical or chemical etching of the layers, e.g. to produce a patterned layer from a pre-deposited extensive layer by chemical means only by vapour etching only using plasmas
Definitions
- the present invention relates to semiconductor device manufacturing technology. More specifically, the present invention relates to a method for preventing corrosion of a metal layer in a semiconductor device, thereby enabling improvement of the reliability and yield of a semiconductor device.
- a semiconductor device has been developed toward higher integration, miniaturization, and higher operational speed.
- Processes of forming aluminum wiring generally comprise the steps of: forming an aluminum layer; coating and patterning a photoresist on the aluminum layer; etching an exposed portion of the aluminum layer (i.e., which is not covered with the photoresist) by means of plasma including chlorine; and removing the photoresist.
- FIGS. 1 a to 1 c are cross-sectional views of a semiconductor device illustrating a conventional method for forming an aluminum wiring in the semiconductor device.
- a photoresist is coated and patterned over a substrate 100 on which an oxide layer 102 , barrier 104 , aluminum layer 106 and antireflective coating 108 are formed in due order. Then, the antireflective coating 108 , aluminum layer 106 and barrier 104 are dry-etched by means of Reactive Ion Etching (RIE) using a chlorine source gas such as Cl 2 , BCl 3 and the like.
- RIE Reactive Ion Etching
- the patterned photoresist 110 is used as a mask for this etching process.
- the patterned photoresist 110 is removed by means of O 2 plasma ashing process.
- corrosion defects 112 on a surface of aluminum layer 106 may result from circumstances such as fluorine, NH 4 OH, water, etc., working conditions of RIE, cleaning solutions used for removal of a photoresist, and especially chlorine residues occurring during the etch of aluminum layer 106 .
- the corrosion defects 112 deteriorate the electrical performance of the semiconductor device or integrated circuit, or cause failures such as a short circuit thus decreasing the yield of manufacturing the semiconductor device.
- a first method involves cleaning the chlorine residues using deionized water, usually as a spray or in a bath.
- a second method involves evaporating the chlorine residues by heat treatment.
- a third method involves using a plasma containing fluorine.
- the first method has little effect on removal of the chlorine residues, and generally does not prevent the corrosion of aluminum wirings in the long run.
- the second method may produce or result in problems such as hillock formation, segregation, or recrystallization, etc. when the temperature of the heat treatment is over 300° C., which are generally related to the low melting point of aluminum.
- the third method has been disclosed in Japanese Patent Publication No. 83-12343 and Korean Patent Laid-Open Publication No. 2000-27241, which relates to a method for removing chlorine residues by means of an etching gas containing fluorine, and then removing a photoresist through an ashing process.
- this method may result in a problem where undercuts 114 on a titanium-containing layer (e.g., a TiN or TiW barrier) occur due to the fluorine-containing plasma, as shown in FIG. 1 c .
- an underlying oxide layer may be damaged, and the aluminum may be changed to AlF 3 (which can result in metal degradation).
- the reliability of semiconductor device may be conspicuously deteriorated.
- an etching system for the purpose of preventing reaction between chlorine residues and water when a substrate is exposed to air, an etching system is equipped with an ashing chamber so that a process of stripping a photoresist is performed in situ.
- chlorine residues are changed to hydrogen chloride (HCl) by means of H 2 O plasma, and then hydrogen chloride is exhausted by a pump, so that chlorine residues existing on surfaces of aluminum layer are generally removed.
- H 2 O plasma hydrogen chloride
- Korean Patent Publication No. 95-5351 discloses a method for preventing corrosion of a metal layer, comprising a plasma process using mixed gases of oxygen (O 2 ) and ammonia (NH 3 ).
- Korean Patent Laid Open Publication No. 2001-35852 discloses a method for preventing corrosion of a metal layer, comprising the step of exposing an object to plasma formed of mixed gases of H 2 N 2 and oxygen.
- a degree of preventing corrosion of a metal layer depends on a mixture ratio of gases.
- these methods tend to have little effect on the prevention of corrosion.
- an object of the present invention to provide a method for preventing metal corrosion in a semiconductor device (and, in one embodiment, simultaneously preventing formation of a bridge between metal wirings), thereby improving the profile of metal layer and the reliability and yield of the semiconductor device.
- a method for preventing metal corrosion of a metal layer in a semiconductor device or integrated circuit comprises the steps of: etching a metal layer in a chamber, the metal layer having a photoresist pattern thereon or thereover; oxidizing a surface of the metal layer using a plasma comprising N 2 O in the chamber; and removing the photoresist.
- the present method further includes the step of removing a portion of the oxidized metal surface by sputter etching using an inert gas, after the step of oxidizing the surface of the metal layer.
- the inert gas includes at least one member of the group consisting of He, Ne, Ar, Kr, Xe and Rn.
- the metal layer preferably comprises one or more layers consisting essentially of aluminum or an aluminum alloy (e.g., aluminum-copper or aluminum-silicon alloy).
- the etch of the metal layer may be performed by dry etching using a plasma which includes chlorine.
- the metal layer may have a width greater than a desired or predetermined critical dimension by 50 to 150 ⁇ .
- the oxidized metal surface may have a width or thickness of from 50 to 150 ⁇ .
- the step of removing the photoresist preferably comprises ashing with a plasma including a chlorine source gas (e.g., Cl 2 ) and a hydrofluorocarbon gas (e.g., CHF 3 ).
- a chlorine source gas e.g., Cl 2
- a hydrofluorocarbon gas e.g., CHF 3
- FIGS. 1 a to 1 c illustrate a conventional method for forming an aluminum wiring in a semiconductor device.
- FIGS. 2 a to 2 d illustrate a method for preventing corrosion of a metal layer in a semiconductor device, according to the present invention.
- FIGS. 2 a to 2 d are cross-sectional views of a semiconductor device illustrating a method for preventing a metal corrosion according to the present invention.
- a photoresist 210 is coated and patterned over a substrate 200 on which an oxide layer 202 , barrier 204 , metal layer 206 and antireflective coating 208 are formed in successive order. Then, antireflective coating 208 , metal layer 206 and barrier 204 are dry-etched using a plasma including a chlorine source gas such as Cl 2 , BCl 3 and/or the like. Such dry etching preferably comprises Reactive Ion Etching (RIE).
- RIE Reactive Ion Etching
- Metal layer 206 may comprise a single layer or a plurality of layers, at least one of which preferably consists essentially of aluminum, aluminum alloy (for example, Al—Cu or Al—Ti), aluminum-silicon alloy (for example, Al—Si, Al—Si—Cu, or Al—Ti—Si), and so on.
- aluminum alloy for example, Al—Cu or Al—Ti
- aluminum-silicon alloy for example, Al—Si, Al—Si—Cu, or Al—Ti—Si
- materials are not limited to these metals or alloys thereof, and any metal or alloy thereof is available for the metal layer 206 in the present invention.
- a metal layer 206 comprises aluminum
- an aluminum layer may be weak for electromigration because aluminum has a relatively low melting point of around 660° C.
- atoms of aluminum may be apt to move due to movement of electrons.
- a barrier 204 comprising or consisting essentially of Ti, TiN, W or TiW can be formed under an aluminum layer.
- barrier 204 consists essentially of a Ti/TiN bilayer.
- an antireflective coating 208 comprising or consisting essentially of TiN or a Ti/TiN bilayer is preferably formed on the aluminum layer 206 , which can suppress or prevent hillock formation, electromigration and stress migration of the aluminum layer 206 , thus improving the reliability of the wiring.
- Barrier 204 and antireflective coating 208 are optional components, not indispensable components.
- a width W of a metal layer 206 is preferably wider than the desired (or predetermined) critical dimension by 50 to 150 ⁇ . Generally, that width corresponds to or is considered for a thickness of a lateral metal oxide to be formed in a subsequent process (e.g., plasma oxidation). In a conventional etching process, metal layer 206 may be overetched to a limited extent. However, in this embodiment according to the present invention, metal layer 206 is not overetched, so that portions of oxide layer 202 below metal layer 206 are not etched.
- a surface of metal layer 206 (e.g., exposed as a result of the metal etching step) is oxidized using a plasma comprising N 2 O.
- the oxidation may be performed in the same chamber as the etching process for metal layer 206 .
- the metal etch and oxidation steps may be performed continuously, or oxidation may be conducted in situ.
- lateral surfaces of a metal layer 206 are oxidized so that lateral oxides 212 are formed.
- the lateral oxides 212 may have a width (or thickness) of from around 50 ⁇ to around 150 ⁇ .
- Chlorine residues remaining or existing on lateral surfaces of metal layer 206 after the metal etch step are oxidized and removed by the N 2 O-containing plasma.
- the present method further includes the steps of: exposing metal surfaces that may have chlorine residues thereon to an H 2 O-containing plasma before oxidization using the N 2 O-containing plasma, so as to change the chlorine residues to hydrogen chloride (or other volatile species); and exhausting the hydrogen chloride and/or other volatile, chlorine-containing species.
- Sputter etching or ion beam etching is a method for physically etching a target by means of accelerating ions in a plasma state which are changed from an inert gas.
- a portion of lateral oxides 212 is removed (e.g., the vertically exposed portions of lateral oxides 212 ) and a portion of oxide layer 202 is also etched at the same time.
- the formation of a bridge or short circuit between adjacent metal lines, sometimes known as a “stringer” can be suppressed or prevented, thereby improving a profile of metal layer 206 .
- a photoresist 210 is partially removed.
- the inert gas comprises at least one of the noble gases (i.e., He, Ne, Ar, Kr, Xe and Rn).
- photoresist 210 is removed.
- a chlorine source gas e.g., Cl 2 , BCl 3 , HCl, etc., preferably Cl 2
- the chamber for forming the ashing plasma has working conditions of: a pressure of from about 0.7 to about 1.3 Torr; an electric power of from about 800 to about 1700 W; an operating time of from about 20 to about 80 seconds; and a temperature less than room temperature.
- the above-described embodiment according to the present invention has explained a series of processes, comprising the steps of: etching a metal layer in a chamber, the metal layer having thereon or thereover a predetermined photoresist pattern; oxidizing surfaces of the metal layer using a N 2 O-containing plasma; removing a portion of the oxidized metal layer surfaces and simultaneously etching an exposed oxide layer by sputter etching using an inert gas; and removing the photoresist by plasma ashing.
- the step of sputter etching using an inert gas may be omitted.
- the method according to the present invention may comprise the following steps of: etching a metal layer under a photoresist pattern; oxidizing surfaces of the metal layer with a plasma comprising N 2 O; and removing the photoresist by plasma ashing.
- a metal layer is dry-etched, lateral oxides are formed using a N 2 O-containing plasma in situ, and then portions of the lateral oxides and an oxide layer (exposed as a result of the metal etch) are simultaneously removed by sputter etching using an inert gas. Therefore, metal corrosion and bridges (a type of short circuit between adjacent metal lines) can be suppressed or prevented, improving a profile of the metal layer. Moreover, undercuts into a barrier layer, damage to an oxide layer and/or deformation of the metal layer can be suppressed or prevented. As a result, the present invention may improve the reliability and yield of a semiconductor device.
Abstract
Description
Claims (19)
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KR1020040056363A KR100584485B1 (en) | 2004-07-20 | 2004-07-20 | Method for preventing metal corrosion of semiconductor devices |
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